New England Hybrid Festival 2013
Mikes You Tube Videos
Mikes Saturday Hybrid-Solar- Electric Workshop
Insight 20 AH lithium battery system
assembling the pack core
BMS board mounting position?
Capturing the mounting boss positions
Cell tester is modified and lithium test fixture takes shape.
Charging experiments
Cleaning the cell tabs
fixing and deburring the heat spreaders
Final assembled pack core
Finishing the connection blocks
finishing the fins and end plates
First discharge graph
Getting started on the final design and build
Heat sink fins
heatsink vs no heatsink comparison
Higher thermal sensitivity look at the cell heating still shows no dents
Hot and cold cells compared.
How do the big guys do it
Is using this asking for a problem?
main I/O terminals and Heat shrink
Making the 50 insulating strips
Painted cells to increase emissivity
Punching the holes in the tabs
Same discharge with huge heat sink on one side of cell
Testing the fans and layout of the BMS boards
The Battery case starts to take shape
The case is nearly finished
the connector plate is made and mounted
The tab punch
The world in IR Cool
Grid charger Users page
Mikes Surplus Loft
Renewable energy exhibits
New England Hybrid festival 2014


making the insulating preforms

As shown below, the biggest issue with assembling the pack safely with charged batteries is keeping all the junctions between cells separated until they can be properly supported. The shaped heat shrink seems to do the job, so I made a new inner form out of pine to make a bunch of the insulators.
The remaining shrink had a lot to do with how distorted the rectangular shape got when the final shrink took place. It seems that using a larger shrink tube using most of the shrink to achieve the preform was much better than only shrinking a small amount to achieve the preform, so I used the larger white shrink.